ESAB A2 TFD1 / A2 TGD1 User manual

Page is loading ...

-- 2 --

Rätt till ändring av specifikationer utan avisering förbehålles.

Ret til ændring af specifikationer uden varsel forbeholdes.

Rett til å endre spesifikasjoner uten varsel forbeholdes.

Oikeudet muutoksiin pidätetään.

Rights reserved to alter specifications without notice.

Änderungen vorbehalten.

Sous réserve de modifications sans avis préalable.

Recht op wijzigingen zonder voorafgaande mededeling voorbehouden.

Reservado el derecho de cambiar las especificaciones sin previo aviso.

Ci riserviamo il diritto di variare le specifiche senza preavviso.

Reservamo--nos o direito de alterar as especificações sem aviso prévio.

Äéáôçñåßôáé ôï äéêáßùìá ôñïðïðïßçóçò ðñïäéáãñáöþí ×ùñßò ðñïåéäïðïßçóç.

SVENSKA 3..............................................

DANSK 12................................................

NORSK 21................................................

SUOMI 30................................................

ENGLISH 39..............................................

DEUTSCH 49.............................................

FRANÇAIS 59.............................................

NEDERLANDS 69.........................................

ESPAÑOL 79..............................................

ITALIANO 89..............................................

PORTUGUÊS 99..........................................

ÅËËÇÍÉÊÁ 109.............................................

Page is loading ...

DANSK

TOCd

-- 1 2 --

1DIREKTIV 13.........................................................

2 SIKKERHED 13.......................................................

3 INDLEDNING 14......................................................

3.1 Teknisk beskrivelse 14........................................................

3.2 Tekniske data 15.............................................................

4 INSTALLATION 15....................................................

5 DRIFT 18.............................................................

6 VEDLIGEHOLDELSE 19...............................................

7 FEJLFINDING 20......................................................

ANVENDELSESOMRÅDE 119..............................................

MÅLSKITSE 122........................................................

SLIDDELE 123..........................................................

RESERVEDELSFORTEGNELSE 125........................................

Page is loading ...

-- 4 0 --

dha2d1ea

1 DIRECTIVE

DECLARATION OF CONFORMIT Y

Esab Welding Equipment AB, 695 81 Laxå, Sweden, gives its unreserved guarantee

that automatic welding machine A2 TFD1 / A2 T GD1 from serial number 452 com -

plies with standard EN 60292, in accordance with the requirements of directive

(89/392/EEA) and addendum.

-- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- --------

Paul Karlsson

Managing Director

Esab Welding Equipment AB

695 81 LAXÅ

SWEDEN Tel: + 46 584 81000 Fax: + 46 584 12336

Laxå 97--07--14

2SAFETY

Users of ESAB automatic welding machines have ultimate responsibility for ensuring that anyone who

works on or near the equipment observes all the relevant safety precautions.

The following recommendations should be observed in addition to the standard regulations that apply

to the work place.

All work must be carried out according to the specified instructions by personnel who are thoroughly

familiar with the operation of the welding machine.

Incorrect or unintentional operation of the equipment may lead to a hazardous situation which can

result in injury to the operator and damage to the equipment.

1. Anyone who uses the automatic welding machine must be familiar with:

S its operation

S the location of emergency stops

S its function

S relevant safety precautions

2. The operator must ensure that:

S no unauthorized person is stationed within the working area of the machine when it is started

up.

S that no--one is in a hazardous position when the carriage or slide mechanisms are operated.

3. The work place must:

S be clear of mechanical components, tools, or other obstructions that could prevent the oper-

ator from moving freely within the working area.

S be organized so that there is free access to the emergency stop.

4. Personal safety equipment

S Always wear recommended personal safety equipment, such as safety glasses, flame--proof

clothing, safety gloves.

S Do not wear loose--fitting items, such as scarves, bracelets, etc., which could become

trapped.

5. General precautions

Live electrical components are normally shielded from accidental contact.

S Make sure the return cable is connected securely.

S Work on high voltage components may only be carried out by a qualified electrician.

S Appropriate fire extinguishing equipment must be clearly marked and close at hand.

S Lubrication and maintenance must not be carried out on the equipment during its operation.

GB

-- 4 1 --

dha2d1ea

WARNING

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERAT ING.

ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAU-

TIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE

BASED ON MANUFACTURERS’ HAZARD DATA.

ELECTRIC SHOCK -- Can kill

S Install and earth the welding unit in accordance with applicable standards.

S Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.

S Insulate yourself from earth and the workpiece.

S Ensure your working stance is safe.

FUMES AND GASES -- Can be dangerous to health

S Keep your head out of the fumes.

S Use ventilation, extraction at the arc, or both, to keep fumes and gases from your breathing zone and

the general area.

ARC RAYS -- Can injure eyes and burn skin.

S Protect your eyes and body. Use the correct welding screen and filter lens and wear protective

clothing.

S Protect bystanders with s uitable screens or curtains.

FIRE HAZARD

S Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.

NOISE -- Excessive noise can damage hearing

S Protect your ears. Use ear defenders or other hearing protection.

S Warn bystanders of the risk.

MALFUNCTION -- Call for expert assistance in the event of malfunction.

PROTECT YOURSELF AND OTHERS!

3 INTRODUCTION

3.1 General

The A2 Multitrac automatic welding machine has four--wheel drive and is designed

for MIG/MAG and UP welding of butt and fillet joints (with direct or alternating

current).

All other applications are prohibited.

When dismantled (with post and safety chain removed) the automatic welding

machine can be inserted through a hole with a minimum diameter of 600 mm.

The position of the contact tip can be adjusted both horizontally and vertically by

means of a slide m echanism. The angle is adjusted by rotating the wire feed unit.

GB

-- 4 2 --

dha2d1ea

3.2 Technical data

A2 MULTITRAC UP MIG/MAG

Supply voltage 42 V AC 42 V AC

Rating 800 A DC 600 A DC

Wire sizes:

steel

stainless

hollow wire

aluminium

1,6--4,0 mm

1,0--1,6 mm

1,6--3,2 mm

1,0--2,4 mm

Wire feed speed, max 9m/min 16 m/min

Brake hub braking torque 1,5 Nm 1,5 Nm

T ravel speed 0,1--1,7 m/min 0,1--1,7 m/min

T urning radius for circumferential welding, min 1500 mm 1500 mm

Pipe diameter for internal joint welding, min 1100 mm 1100 mm

Electrode weight, max 30 kg 30 kg

Flux container volume

(Must not be filled with preheated powder)

6l

Weight (excl. wire and flux) 47 kg 47 kg

T ransverse inclination, max

25_ 25_

Continuous A--weighted noise pressure 68 dB 83 dB

See dimension drawing on page 122.

GB

-- 4 3 --

dha2d1ea

4 INSTALLATION

WARNING!

Rotating parts can cause injury, take great care.

1. Control box PEG1, see instruction manual 443 392.

2. Connect the automatic welding machine as shown in the drawing on page 43

and on page 44.

SUBMERGED ARC WELDING

S Connect the control cable (2) between the power source (7) and the control

box PEG1.

S Connect the return cable (3, 4, 5) between the power source (7) and work

piece.

S Connect the cable (3, 4, 5) between the power source (7) and shunt.

S Connect the measurement cable (6) between the power source (7) and work

piece.

GB

-- 4 4 --

dha2d1ea

ARC WELDING MIG/MAG

S Connect the control cable ( 6) between the power source (7) and control box

PEG1.

S Connect the return cable (8, 9, 10) between the power source (7) and work

piece.

S Connect the cable (8, 9, 10) between the power source (7) and shunt.

S Connect the measurement cable (11) between the power source (7) and

work piece.

S Connect the gas hose (4) between the reducer valve (5) and the gas

connection (1) on the welding machine.

S Connect the cooling water hoses (2) between the cooling unit (3) and the

welding machine (1).

3. Choose the wire and flux (gas) to give a weld metal analysis that matches the

work piece fairly closely. Choose the wire size and welding parameters in

accordance with the recommendations of the consumable manufacturer.

4. Loading with welding wire.

S Remove the wire reel from the hub (2) and remove the

end plate (3).

S Place the coil of wire (1) on the reel and fit the end plate (3).

S Fit the wire reel and disposable reel on the hub (2).

NOTE the position o f the stud.

IMPORTANT!

To prevent the reel sliding off the hub: Lock the reel in place

by turning the red knob as shown on the warning label atta-

ched next to the hub.

GB

dha20001

-- 4 5 --

dha2d1ea

S Check that the wire feed roller (1) and

contact jaws (4) are the correct size.

S Guide the wire through the two small bolt

eyes.

S Insert the end of the wire into the

groove in the feed roller.

S Adjust the feed roller pressure on the wire

using the adjuster screw (6).

NOTE! Tighten only enough to ensure smooth wire

feed. Do not tighten the adjuster screw all the way,

there must be some play left.

S Feed the wire through using switch A 02 on the

PEG box.

S While the wire is being fed through, straighten it out by

adjusting the knob (5) on the wire straightener, or by

using a special wir e straightener for thin wire or twin

wire. When the wire straightener is correctly adjusted

the wire should come straight out between the contact

jaws and contact tip.

5. Changing the wire feed roller (see wear components on page 123).

S Single wire:

S Loosen the knob (5) and adjuster screw (6).

S Undo the hand wheel (2).

S Change the feed roller. T he wire size is m arked on the rollers.

S Twin wire:

S Change feed rollers with twin grooves in the same way as for single wire.

S NOTE! Change the pressure roller at the same time. T he special

spherical roller for twin wire replaces the standard pressure roller for

single wire.

S Fit the pressure roller using the special shaft stud

(order no. 146 253--001).

S Hollow wire:

S Replace the feed roller and pressure roller with rollers of the correct size.

NOTE! A special shaft stud is required for the pressure roller

(order no. 2129 011--01).

S Tighten the adjusting screw to a moderate pressure so that the wire is

not deformed.

6. Position the flux nozzle so that it does not catch and provides a good coverage

of flux (Sub--arc welding).

N.B! The lenght of the flux delivery hose is to be adapted to the welding head

position.

7. Check that the wheels of the carriage do not come closer than 50 mm to the

weld during welding.

GB

-- 4 6 --

dha2d1ea

8. Filling with flux (Sub--arc welding).

S Close the flux valve on the flux container.

S Remove the separator, if fitted, from the flux recovery unit. F ill with flux.

NOTE! The flux must be dry. If possible, avoid using agglomerated flux

outdoors or in damp conditions.

S Adjust the height of the flux nozzle above the weld to give sufficient

coverage. The flux covering should be deep enough to prevent the arc

breaking through.

9. It is easier to move the carriage if the wheels are released by turning knob A

anticlockwise (see dimension drawing on page 122).

5 OPERATION

General safety regulations for the handling of the equipment appear from

page 40. Read through before you start using the equipment!

1. Careful joint preparation is essential for good welding results.

NOTE! The gap in the weld joint must be uniform.

2. To minimize the risk of hot cracking the width of the weld should be larger than

the penetration.

3. Always weld a test piece with the same joint preparation and plate thickness as

the intended production piece.

NOTE! NEVER makeatrialweldonaproductionworkpiece.

Operating instructions for control box PEG1

See operating manual PEG1 order no. 443 392.

GB

aza5dp08

-- 4 7 --

dha2d1ea

6 MAINTENANCE

1. Control box PEG1, see instruction manual 443 392.

2. For conversion from Sub--arc to MIG/MAG see conversion kit 413 526--880.

3. Daily

S Clean flux and dirt off m oving parts of the welding machine.

S Check that the contact tip and all electrical cables are connected.

S Check that all bolted joints are tight and that guides and drive rollers are not

worn or damaged.

4. Periodically

S Check the wire feed unit wire guides, drive rollers and contact tip.

Replace worn or damaged components.

(See wear components on page 123)

S Check the slides and lubricate if stiff.

S Lubricate the chain

5. Tensioning the carriage chain between front axle and rear axle.

S Remove the carriage wheels. Undo the Y--flange bearing bolts.

S Tension the chain by moving the rear axle backwards so that it remains par-

allel with the front axle.

S Reassemble in reverse order.

6. Tensioning the carriage chain between the front axle and drive motor with gear.

S Tension the chain by moving the drive motor and gear.

7. Check the brake hub braking torque. It should not be so low, that the wire reel

continues to rotate when wire feed is stopped and it should not be so great that

the feed rollers slip. As a guide, the braking torque for a 30 kg wire reel should

be 1,5 Nm.

S Adjusting the braking torque:

S Set the locking button ( 006)

to the locked position.

S Insert a screwdriver into

the hub springs. Turning the

springs (002) clockwise

reduces the braking

torque. Turning the springs anticlockwise increases the torque.

NOTE! Turn the springs by the same amount.

GB

-- 4 8 --

dha2d1ea

7 FAULT TRACING

Equipment

S Instruction manual control box PEG 1, order no. 443 392.

Check

S that the power supply is connected for the correct mains supply

S that all three phases are supplying the correct voltage (phase se-

quence is not important)

S that welding cables and connections are not damaged

S that the controls are correctly set

S that the mains supply is disconnected before starting repairs

POSSIBLE FAULTS

1. Symptom Current and voltage readings show large fluctuations.

Cause 1.1 Contact jaws or nozzle are worn or wrong size.

Action Replace contact jaws or nozzle.

Cause 1.2 Feed roller pressure is inadequate.

Action Increase pressure on feed rollers.

2. Symptom Wire feed is irregu lar.

Cause 2.1 Pressure on feed rollers incorrectly set.

Action Adjust pressure on feed rollers.

Cause 2.2 Feed rollers wrong size.

Action Replace feed rollers.

Cause 2.3 Grooves in feed rollers are worn.

Action Replace feed rollers.

3. Symptom Weldin g cables overheating.

Cause 3.1 Poor electrical connection.

Action Clean and tighten all electrical connections.

Cause 3.2 Cross--sectional area of welding cables too small.

Action Use cables with a larger cross --section or use parallel cables.

GB

Page is loading ...

NEDERLANDS

TOCh

-- 6 9 --

1 RICHTLIJN 70........................................................

2 VEILIGHEID 70.......................................................

3 INLEIDING 71.........................................................

3.1 Algemeen 71................................................................

3.2 Technische gegevens 72......................................................

4 INSTALLATIE 73......................................................

5 INGEBRUIKNAME 76..................................................

6 ONDERHOUD 77......................................................

7 STORINGZOEKEN 78.................................................

TOEPASSINGSGEBEID 119................................................

MAATSCHETS 122........................................................

SLIJTAGEONDERDELEN 123..............................................

RESERVEONDERDELENLIJST 125.........................................

Page is loading ...

ESPAÑOL

TOCc

-- 7 9 --

1NORMATIVA 80.......................................................

2 SEGURIDAD 80.......................................................

3 INTRODUCCION 81...................................................

3.1 Generalidades 81............................................................

3.2 Datos técnicos 82............................................................

4 INSTALACIÓN 83.....................................................

5 OPERACIÓN 86.......................................................

6 MANTENIMIENTO 87..................................................

7 LOCALIZACIÓN DE AVERÍAS 88.......................................

SETTORE DI APPLICACIONE 119..........................................

CROQUIS ACOTADO 122..................................................

PIEZAS DE DESGASTE 123...............................................

LISTA DE REPUESTOS 125................................................

Page is loading ...

ITALIANO

TOCi

-- 8 9 --

1 DIRETTIVA 90........................................................

2 SICUREZZA 90.......................................................

3 INTRODUZIONE 91...................................................

3.1 Generalità 91................................................................

3.2 Dati tecnici 92...............................................................

4 INSTALLAZIONE 93...................................................

5USO 96..............................................................

6 MANUTENZIONE 97...................................................

7 RICERCA GUASTI 98.................................................

SETTORE DI APPLICAZIONE 119.........................................

DIMENSIONI 122..........................................................

PARTI DI USURA 123.....................................................

ELENCO RICAMBI 125....................................................

Page is loading ...

Reservdelsförteckn in g Reservedelsfortegnelse Reservedelsliste

Varaosaluettelo Spare parts list Ersatzteilliste L iste de pièces détachées

Reserveonderdelenlijst Lista de repuestos Elenco ricambi Lista de peças

sobressalentes Ðßíáêáò áíôáëëáêôéêþí ìåñþí

ÐÉíáÊ ÁÓ áíôáë ë áêôéêÙí ì åñ Ùí

-- 125 --

dha2r11a

Edition 9612

Ordering no. Denomination Notes

413 300--880 A2 Multitrac Automatic welding machine UP

413 400--880 A2 Multitrac Automatic welding machine MIG/MAG

C = Component designation in the circuit diagram

-- 126 --

dha2r11a

Item

no.

Qty Orderingno. Denomination Notes C

413 300--880 Automatic welding machine UP

01 1 413 596--888 Wire feed mechanism compl. (right)

03 4 190 437--370 Screw M6x20

04 10 2151 000--13 Washer D12/6.4x1.5

05 1 413 318--001 Holder

06 2 192 238--461 Screw M8x50

07 2 2151 002--02 Washer D26/8.4x5

10 1 332 994--883 Flux hopper

11 1 333 094--880 Clamp

12 1 332 948--001 Fluz tube

13 1 413 510--001 Centact tube

14 2 413 518--880 Slide

15 1 413 506--880 Rotary slide

18 2 162 414--004 Insulating tube

21 11 190 452--165 Washer D18/8.4x1.5

22 3 2126 031--04 Nut M8

25 1 413 317--001 Handle

26 1 413 530--880 Boom

27 1 413 540--001 Clamp

28 1 413 528--001 Column

29 1 413 525--001 Insulating tube

30 1 156 442--002 Clamp screw

31 1 192 238--380 Screw M6x50

32 2 190 452--178 Washer D24/13x2

33 6 162 414--002 Insulating tube

34 1 192 238--463 Screw M8x60

35 2 2183 01 1--13 Lifting eye bolt

36 1 333 001--891 Control box

38 4 2121 107--17 Screw B8x9.5

39 2 2121 089--03 Screw M6x12

40 4 2126 01 1--07 Nut M6

41 1 413 538--001 Plate

42 1 413 535--001 Bracket

43 3 192 238--366 Screw M6x12

44 1 413 537--001 Mounting plate

45 1 415 855--880 Carriage

47 4 192 238--372 Screw M6x25

48 1 413 534--001 Attachment

49 6 163 139--002 Bushing

52 1 413 527--001 Plate

53 4 192 238--455 Screw M8x30

54 1 413 539--002 Foot clamp

55 1 193 570--131 Locking arm

56 2 2151 000--23 Washer D22/10.5x2

57 1 153 872--880 Wire reel

-- 127 --

dha2r11a

Item

no.

CNotesDenominationOrderingno.Qty

58 1 146 967--880 Brake hub

59 1 413 532--001 Attachment

60 1 192 238--489 Screw M10x16

61 1 413 597--001 Fuse chain

62 1 413 671--001 Chain attachment

66 1 416 984--880 Guide pin, compl.

-- 128 --

dha2r11a

Item

no.

Qty Orderingno. Denomination Notes C

413 300--881 Automatic welding machine UP

02 1 413 596--884 Wire feed mechanism compl. (left)

03 4 190 437--370 Screw M6x20

04 10 2151 000--13 Washer D12/6.4x1.5

05 1 413 318--001 Holder

06 2 192 238--461 Screw M8x50

07 2 2151 002--02 Washer D26/8.4x5

10 1 332 994--883 Flux hopper

11 1 333 094--880 Clamp

12 1 332 948--001 Fluz tube

13 1 413 510--001 Centact tube

14 2 413 518--880 Slide

15 1 413 506--880 Rotary slide

18 2 162 414--004 Insulating tube

21 11 190 452--165 Washer D18/8.4x1.5

22 3 2126 031--04 Nut M8

25 1 413 317--001 Handle

26 1 413 530--880 Boom

27 1 413 540--001 Clamp

28 1 413 528--001 Column

29 1 413 525--001 Insulating tube

30 1 156 442--002 Clamp screw

31 1 192 238--380 Screw M6x50

32 2 190 452--178 Washer D24/13x2

33 6 162 414--002 Insulating tube

34 1 192 238--463 Screw M8x60

35 2 2183 01 1--13 Lifting eye bolt

36 1 333 001--891 Control box

38 4 2121 107--17 Screw B8x9.5

39 2 2121 089--03 Screw M6x12

40 4 2126 01 1--07 Nut M6

41 1 413 538--001 Plate

42 1 413 535--001 Bracket

43 3 192 238--366 Screw M6x12

44 1 413 537--001 Mounting plate

45 1 415 855--880 Carriage

47 4 192 238--372 Screw M6x25

48 1 413 534--001 Attachment

49 6 163 139--002 Bushing

51 2 190 232-- 103 Rivet

52 1 413 527--001 Plate

53 4 192 238--455 Screw M8x30

54 1 413 539--002 Foot clamp

55 1 193 570--131 Locking arm

56 2 2151 000--23 Washer D22/10.5x2

-- 129 --

dha2r11a

Item

no.

CNotesDenominationOrderingno.Qty

57 1 153 872--880 Wire reel

58 1 146 967--880 Brake hub

59 1 413 532--001 Attachment

60 1 192 238--489 Screw M10x16

61 1 413 597--001 Fuse chain

62 1 413 671--001 Chain attachment

66 1 416 984--880 Guide pin, compl.

-- 130 --

dha2r11a

Item

no.

Qty Orderingno. Denomination Notes C

413 400--880 Automatic welding machine MIG/MAG

01 1 413 596--889 Wire feed mechanism compl. (right)

03 4 190 437--370 Screw M6x20

04 10 2151 000--13 Washer D12/6.4x1.5

05 1 0304 653--89 Connector

06 1 192 238--461 Screw M8x50

07 1 162 414--004 Insulating tube

12 4 2151 001--03 Washer D16/8.4x3

14 2 413 518--880 Slide

15 1 413 506--880 Rotary slide

18 1 155 300--001 Plate

19 2 192 238--449 Screw M8x16

21 9 190 452--165 Washer D18/8.4x1.5

22 2 2126 031--04 Nut M8

23 1 156 800--002 Hose L = 1000

25 1 413 317--001 Handle

26 1 413 530--880 Boom

27 1 413 540--001 Clamp

28 1 413 528--001 Column

29 1 413 525--001 Insulating tube

30 1 156 442--002 Clamp screw

31 1 1922 383--80 Screw M6x50

32 2 190 452--178 Washer D24/13x2

33 6 162 414--002 Insulating tube

34 1 192 238--463 Screw M8x60

35 2 2183 01 1--13 Lifting eye bolt

36 1 333 001--891 Contral box

38 4 2121 107--17 Screw B8x9.5

39 2 2121 089--03 Screw M6x12

40 4 2126 01 1--07 Nut M6

41 1 413 538--001 Plate

42 1 413 535--001 Bracket

43 3 192 238--366 Screw M6x12

44 1 413 537--001 Mounting plate

45 1 415 855--880 Carriage

47 4 192 238--372 Screw M6x25

48 1 413 534--001 Attachment

49 5 163 139--002 Bushing

52 1 413 527--001 Plate

53 4 192 238--455 Screw M8x30

54 1 413 539--002 Foot clamp

55 1 193 570--131 Locking arm

56 2 2151 000--23 Washer D22/10.5x2

57 1 193 054--002 Solenoid valve

58 1 146 967--880 Drake hub

Page is loading ...

ESAB A2 TFD1 / A2 TGD1 User manual

ESAB A2 TFD1 / A2 TGD1 User manual

in other languages

Related papers

Other documents